Fan array fan section in air-handling systems

ABSTRACT

A fan array fan section in an air-handling system includes a plurality of fan units arranged in a fan array and positioned within an air-handling compartment. One preferred embodiment may include an array controller programed to operate the plurality of fan units at peak efficiency. The plurality of fan units may be arranged in a true array configuration, a spaced pattern array configuration, a checker board array configuration, rows slightly offset array configuration, columns slightly offset array configuration, or a staggered array configuration.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of application Ser. No. 11/595,212,filed Nov. 9, 2006 now U.S. Pat. No. 7,527,468, which is aContinuation-in-Part of application Ser. No. 10/806,775, filed Mar. 22,2004, now U.S. Pat. No. 7,137,775 which is a continuation in part ofPCT/US04/08578, filed Mar. 19, 2004 and claims benefit of 60/456,413,filed Mar. 20, 2003 and 60/554,702, filed Mar. 20, 2004.

BACKGROUND OF INVENTION

The present invention is directed to a fan array fan section utilized inan air-handling system.

Air-handling systems (also referred to as an air handler) havetraditionally been used to condition buildings or rooms (hereinafterreferred to as “structures”). An air-handling system is defined as astructure that includes components designed to work-together in order tocondition air as part of the primary system for ventilation ofstructures. The air-handling system may contain components such ascooling coils, heating coils, filters, humidifiers, fans, soundattenuators, controls, and other devices functioning to meet the needsof the structures. The air-handling system may be manufactured in afactory and brought to the structure to be installed or it may be builton site using the necessary devices to meet the functioning needs of thestructure. The air-handling compartment 102 of the air-handling systemincludes the inlet plenum 112 prior to the fan inlet cone 104 and thedischarge plenum 110. Within the air-handling compartment 102 issituated the fan unit 100 (shown in FIGS. 1 and 2 as an inlet cone 104,a fan 106, and a motor 108), fan frame, and any appurtenance associatedwith the function of the fan (e.g. dampers, controls, settling means,and associated cabinetry). Within the fan 106 is a fan wheel (not shown)having at least one blade. The fan wheel has a fan wheel diameter thatis measured from one side of the outer periphery of the fan wheel to theopposite side of the outer periphery of the fan wheel. The dimensions ofthe handling compartment 102 such as height, width, and airway lengthare determined by consulting fan manufacturers data for the type of fanselected.

FIG. 1 shows an exemplary prior art air-handling system having a singlefan unit 100 housed in an air-handling compartment 102. For exemplarypurposes, the fan unit 100 is shown having an inlet cone 104, a fan 106,and a motor 108. Larger structures, structures requiring greater airvolume, or structures requiring higher or lower temperatures havegenerally needed a larger fan unit 100 and a generally correspondinglylarger air-handling compartment 102.

As shown in FIG. 1, an air-handling compartment 102 is substantiallydivided into a discharge plenum 110 and an inlet plenum 112. Thecombined discharge plenum 110 and the inlet plenum 112 can be referredto as the airway path 120. The fan unit 100 may be situated in thedischarge plenum 110 as shown), the inlet plenum 112, or partiallywithin the inlet plenum 112 and partially within the discharge plenum110. The portion of the airway path 120 in which the fan unit 100 ispositioned may be generically referred to as the “fan section”(indicated by reference numeral 114). The size of the inlet cone 104,the size of the fan 106, the size the motor 108, and the size of the fanframe (not shown) at least partially determine the length of the airwaypath 120. Filter banks 122 and/or cooling coils (not shown) may be addedto the system either upstream or downstream of the fan units 100.

For example, a first exemplary structure requiring 50,000 cubic feet perminute of air flow at six (6) inches water gage pressure would generallyrequire a prior art air-handling compartment 102 large enough to house a55 inch impeller, a 100 horsepower motor, and supporting framework. Theprior art air-handling compartment 102, in turn would be approximately92 inches high by 114 to 147 inches wide and 106 to 112 inches long. Theminimum length of the air-handling compartment 102 and/or airway path120 would be dictated by published manufacturers data for a given fantype, motor size, and application. Prior art cabinet sizing guides showexemplary rules for configuring an air-handling compartment 102. Theserules are based on optimization, regulations, and experimentation.

For example, a second exemplary structure includes a recirculation airhandler used in semiconductor and pharmaceutical clean rooms requiring26,000 cubic feet per minute at two (2) inches-water gage pressure. Thisstructure would generally require a prior art air-handling system with aair-handling compartment 102 large enough to house a 44 inch impeller, a25 horsepower motor, and supporting framework. The prior artair-handling compartment 102, in turn would be approximately 78 incheshigh by 99 inches wide and 94 to 100 inches long. The minimum length ofthe air-handling compartment 102 and/or airway path 120 would bedictated by published manufacturers data for a given fan type, motorsize and application. Prior art cabinet sizing guides show exemplaryrules for configuring an air-handling compartment 102. These rules arebased on optimization, regulations, and experimentation.

These prior art air-handling systems have many problems including thefollowing exemplary problems:

-   -   Because real estate (e.g. structure space) is extremely        expensive, the larger size of the air-handling compartment 102        is extremely undesirable.    -   The single fan units 100 are expensive to produce and are        generally custom produced for each job.    -   Single fan units 100 are expensive to operate.    -   Single fan units 100 are inefficient in that they only have        optimal or peak efficiency over a small portion of their        operating range.    -   If a single fan unit 100 breaks down, there is no air        conditioning at all.    -   The low frequency sound of the large fan unit 100 is hard to        attenuate.    -   The high mass and turbulence of the large fan unit 100 can cause        undesirable vibration.

Height restrictions have necessitated the use of air-handling systemsbuilt with two fan units 100 arranged horizontally adjacent to eachother. It should be noted, however, that a good engineering practice isto design air handler cabinets and discharge plenums 110 to besymmetrical to facilitate more uniform air flow across the width andheight of the cabinet. Twin fan units 100 have been utilized where thereis a height restriction and the unit is designed with a high aspectratio to accommodate the desired flow rate. As shown in the Greenheck“Installation Operating and Maintenance Manual,” if side-by-sideinstallation was contemplated, there were specific instructions toarrange the fans such that there was at least one fan wheel diameterspacing between the fan wheels and at least one-half a fan wheeldiameter between the fan and the walls or ceilings. The Greenheckreference even specifically states that arrangements “with less spacingwill experience performance losses.” Normally, the air-handling systemand air-handling compartment 102 are designed for a uniform velocitygradient of 500 feet per minute velocity in the direction of air flow.The two fan unit 100 air-handling systems, however, still substantiallysuffered from the problems of the single unit embodiments. There was norecognition of advantages by increasing the number of fan units 100 fromone to two. Further, the two fan unit 100 section exhibits a non-uniformvelocity gradient in the region following the fan unit 100 that createsuneven air flow across filters, coils, and sound attenuators.

It should be noted that electrical devices have taken advantage ofmultiple fan cooling systems. For example, U.S. Pat. No. 6,414,845 toBonet uses a multiple-fan modular cooling component for installation inmultiple component-bay electronic devices. Although some of theadvantages realized in the Bonet system would be realized in the presentsystem, there are significant differences. For example, the Bonet systemis designed to facilitate electronic component cooling by directing theoutput from each fan to a specific device or area. The Bonet systemwould not work to direct air flow to all devices in the direction ofgeneral air flow. Other patents such as U.S. Pat. No. 4,767,262 to Simonand U.S. Pat. No. 6,388,880 to El-Ghobashy et al. teach fan arrays foruse with electronics.

Even in the computer and machine industries, however, operating fans inparallel is taught against as not providing the desired results exceptin low system resistance situations where fans operate in near freedelivery. For example, Sunon Group has a web page in which they show twoaxial fans operating in parallel, but specifically state that if “theparallel fans are applied to the higher system resistance that [an]enclosure has, . . . less increase in flow results with parallel fanoperation.” Similar examples of teaching against using fans in parallelare found in an article accessible from HighBeam Research's library(http://stati.highbeam.com) and an article by Ian McLeod accessible at(http://www.papstplc.com).

BRIEF SUMMARY OF THE INVENTION

The present invention is directed to a fan array fan section in anair-handling system that includes a plurality of fan units arranged in afan array and positioned within an air-handling compartment. Onepreferred embodiment may include an array controller programmed tooperate the plurality of fan units at peak efficiency. The plurality offan units may be arranged in a true array configuration, a spacedpattern array configuration, a checker board array configuration, rowsslightly offset array configuration, columns slightly offset arrayconfiguration, or a staggered array configuration.

The foregoing and other objectives, features, and advantages of theinvention will be more readily understood upon consideration of thefollowing detailed description of the invention, taken in conjunctionwith the accompanying drawings.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

FIG. 1 is a side view of an exemplary prior art air-handling systemhaving a single large fan unit within an air-handling compartment.

FIG. 2 is a perspective view of an exemplary prior art large fan unit.

FIG. 3 is a side view of an exemplary fan array fan section in anair-handling system of the present invention having a plurality of smallfan units within an air-handling compartment.

FIG. 4 is a plan or elevation view of a 4×6 exemplary fan array fansection in an air-handling system of the present invention having aplurality of small fan units within an air-handling compartment.

FIG. 5 is a plan or elevation view of a 5×5 exemplary fan array fansection in an air-handling system of the present invention having aplurality of small fan units within an air-handling compartment.

FIG. 6 is a plan or elevation view of a 3×4 exemplary fan array fansection in an air-handling system of the present invention having aplurality of small fan units within an air-handling compartment.

FIG. 7 is a plan or elevation view of a 3×3 exemplary fan array fansection in an air-handling system of the present invention having aplurality of small fan units within an air-handling compartment.

FIG. 8 is a plan or elevation view of a 3×1 exemplary fan array fansection in an air-handling system of the present invention having aplurality of small fan units within an air-handling compartment.

FIG. 9 is a plan or elevation view of an alternative exemplary fan arrayfan section in an air-handling system of the present invention in whicha plurality of small fan units are arranged in a spaced pattern arraywithin an air-handling compartment.

FIG. 10 is a plan or elevation view of an alternative exemplary fanarray fan section in an air-handling system of the present invention inwhich a plurality of small fan units are arranged in a checker boardarray within an air-handling compartment.

FIG. 11 is a plan or elevation view of an alternative exemplary fanarray fan section in an air-handling system of the present invention inwhich a plurality of small fan units are arranged in rows slightlyoffset array within an air-handling compartment.

FIG. 12 is a plan or elevation view of an alternative exemplary fanarray fan section in an air-handling system of the present invention inwhich a plurality of small fan units are arranged in columns slightlyoffset array within an air-handling compartment.

FIG. 13 is a plan or elevation view of a 5×5 exemplary fan array fansection in an air-handling system of the present invention running at52% capacity by turning a portion of the fans on and a portion of thefans off.

FIG. 14 is a plan or elevation view of a 5×5 exemplary fan array fansection in an air-handling system of the present invention running at32% capacity by turning a portion of the fans on and a portion of thefans off.

FIG. 15 is a side view of an alternative exemplary fan array fan sectionin an air-handling system of the present invention having a plurality ofstaggered small fan units within an air-handling compartment.

FIG. 16 is a perspective view of an exemplary fan array using a gridsystem into which fan units are mounted.

FIG. 17 is a perspective view of an exemplary fan array using a gridsystem or modular units each of which includes a fan units mountedwithin its own fan unit chamber.

FIG. 18 is a perspective view of an exemplary array of dampeners thatmay be positioned either in front of or behind the fan units.

FIG. 19 is a side view of air flowing between insulation boards with anopen cell foam facing of the present invention, the insulation boardsand open cell foam facing secured by perforated rigid facing.

FIG. 20 is a side view of an insulation board with open cell foamfacings of the present invention such that the fiberglass therein isenclosed in between the facings.

FIG. 21 is a side view of sound being absorbed within an insulationboard with an open cell foam facing of the present invention.

FIG. 22 is an enlarged side view of protruding open cell foam facingformed between the openings in the perforated rigid facing and soundwaves being absorbed by the protruding open cell foam facing.

FIG. 23 is a front view of an exemplary perforated rigid facing havingcircular openings defined therein.

FIG. 24 is a side view of an exemplary air handler having a top sectionwith open cell foam facing secured by perforated rigid facing and abottom section with layered fiberglass and open cell foam facing securedby perforated rigid facing.

FIG. 25 is a front view of open cell foam facing secured by an exemplaryframe.

DETAILED DESCRIPTION OF THE INVENTION

The present invention is directed to a fan array fan section in anair-handling system. As shown in FIGS. 3-12, the fan array fan sectionin the air-handling system uses a plurality of individual single fanunits 200. In one preferred embodiment, the fan units 200 are arrangedin a true array (FIGS. 4-8), but alternative embodiments may include,for example, alternative arrangements such as in a spaced pattern (FIG.9), a checker board (FIG. 10), rows slightly offset (FIG. 11), orcolumns slightly offset (FIG. 12). As the present invention could beimplemented with true arrays and/or alternative arrays, the term “array”is meant to be comprehensive.

The fan units 200 in the fan array of the present invention may bespaced as little as 20% of a fan wheel diameter. Optimum operatingconditions for a closely arranged array may be found at distances as lowas 30% to 60% of a fan wheel diameter. By closely spacing the fan units200, more air may be moved in a smaller space. For example, if the fanwheels of the fan units 200 have a 20 inch fan wheel diameter, only a 4inch space (20%) is needed between the outer periphery of one fan wheeland the outer periphery of the adjacent fan wheel (or a 2 inch spacebetween the outer periphery of a fan wheel and an the adjacent wall orceiling).

By using smaller fan units 200 it is possible to support the fan units200 with less intrusive structure (fan frame). This can be compared tothe large fan frame that supports prior art fan units 100 and functionsas a base. This large fan frame must be large and sturdy enough tosupport the entire weight of the prior art fan units 100. Because oftheir size and position, the known fan frames cause interference withair flow. In the preferred embodiment, therefore, the fan units 200 ofthe fan array may be supported by a frame that supports the motors 108with a minimum restriction to air flow.

As mentioned in the Background, others have tried using side-by-sideinstallation of two fan units 100 arranged horizontally adjacent to eachother within an air-handling system. As is also mentioned in theBackground, fan arrays have been used in electronic and computerassemblies. However, in the air-handling system industry, it has alwaysbeen held that there must be significant spacing between thehorizontally arranged fan wheels and that arrangements with less spacingwill experience performance losses. A single large fan moves all the airin a cabinet. Using two of the same or slightly smaller fans caused theair produced by one fan to interfere with the air produced by the otherfan. To alleviate the interference problem, the fans had to be spacedwithin certain guidelines—generally providing a clear space between thefans of a distance of at least one wheel diameter (and a half a wheeldiameter to an adjacent wall). Applying this logic, it would not havemade sense to add more fans. And even if additional fans had been added,the spacing would have continued to be at least one wheel diameterbetween fans. Further, in the air-handling system industry, verticallystacking fan units would have been unthinkable because the means forsecuring the fan units would not have been conducive to such stacking(they are designed to be positioned on the floor only).

It should be noted that the plenum fan is the preferred fan unit 200 ofthe present invention. In particular, the APF-121, APF-141, APF-161, andAPF-181 plenum fans (particularly the fan wheel and the fan cone)produced by Twin City Fan Companies, Ltd. of Minneapolis, Minn., U.S.has been found to work well. The reason that plenum fans work best isthat they do not produce points of high velocity such as those producedby axial fans and housed centrifugal fans and large plenum fans.Alternative embodiments use known fan units or fan units yet to bedeveloped that will not produce high velocity gradients in the directionof air flow. Still other embodiments, albeit less efficient, use fanunits such as axial fans and/or centrifugal housed fans that have pointsof high velocity in the direction of air flow.

In the preferred embodiment, each of the fan units 200 in the fan arrayfan section in the air-handling system is controlled by an arraycontroller 300 (FIGS. 13 and 14). In one preferred embodiment, the arraycontroller 300 may be programmed to operate the fan units 200 at peakefficiency. In this peak efficiency embodiment, rather than running allof the fan units 200 at a reduced efficiency, the array controller 300turns off certain fan units 200 and runs the remaining fan units 200 atpeak efficiency. In an alternative embodiment, the fan units 200 couldall run at the same power level (e.g. efficiency and/or flow rate) ofoperation.

Another advantage of the present invention is that the array controller300 (which may be a variable frequency drive (VFD)) used for controllingfan speed and thus flow rate and pressure, could be sized for the actualbrake horsepower of the fan array fan section in the air-handlingsystem. Since efficiency of the fan wall array can be optimized over awide range of flow rates and pressures, the actual operating powerconsumed by the fan array is substantially less than the actualoperating power consumed by the comparable prior art air-handlingsystems and the array controller's power could be reduced accordingly.The array controller 300 could be sized to the actual power consumptionof the fan array where as the controller (which may have been a variablefrequency drive) in a traditional design would be sized to the maximumnameplate rating of the motor per Electrical Code requirements. Anexample of a prior art fan design supplying 50,000 cubic feet per minuteof air at 2.5 inches pressure, would require a 50 horsepower motor and50 horsepower controller. The new invention will preferably use an arrayof fourteen 2 horsepower motors and a 30 horsepower array controller300.

This invention solves many of the problems of the prior art air-handlingsystems including, but not limited to real estate, reduced productioncosts, reduced operating expenses, increased efficiency, improved airflow uniformity, redundancy, sound attenuation advantages, and reducedvibration.

Controllability

As mentioned, preferably each of the fan units 200 in the fan array fansection in the air-handling system is controlled by an array controller300 (FIGS. 13 and 14) that may be programmed to operate the fan units200 at peak efficiency. In this peak efficiency embodiment, rather thanrunning all of the fan units 200 at a reduced efficiency, the arraycontroller 300 is able to turn off certain fan units 200 and run theremaining fan units 200 at peak efficiency. Preferably, the arraycontroller 300 is able to control fan units 200 individually, inpredetermined groupings, and/or as a group as a whole.

For example, in the 5×5 fan array such as that shown in FIGS. 5, 13, and14, a person desiring to control the array may select desired airvolume, a level of air flow, a pattern of air flow, and/or how many fanunits 200 to operate. Turning first to air volume, each fan unit 200 ina 5×5 array contributes 4% of the total air. In variable air volumesystems, which is what most structures have, only the number of fanunits 200 required to meet the demand would operate. A control system(that may include the array controller 300) would be used to take fanunits 200 on line (an “ON” fan unit 200) and off line (an “OFF” fan unit200) individually. This ability to turn fan units 200 on and off couldeffectively eliminate the need for a variable frequency drive.Similarly, each fan unit 200 in a 5×5 array uses 4% of the total powerand produces 4% of the level of air flow, Using a control system to takefan units 200 on line and off line allows a user to control power usageand/or air flow. The pattern of air flow can also be controlled if thatwould be desirable. For example, depending on the system it is possibleto create a pattern of air flow only around the edges of a cabinet orair only at the top. Finally, individual fan units 200 may be taken online and off line. This controllability may be advantageous if one ormore fan units 200 are not working properly, need to be maintained (e.g.needs general service), and/or need to be replaced. The problematicindividual fan units 200 may be taken off line while the remainder ofthe system remains fully functional. Once the individual fan units 200are ready for use, they may be brought back on line.

A further advantage to taking fan units 200 on and off line occurs whenbuilding or structure control systems require low volumes of air atrelatively high pressures. In this case, the fan units 200 could bemodulated to produce a stable operating point and eliminate the surgeeffects that sometimes plague structure owners and maintenance staff.The surge effect is where the system pressure is too high for the fanspeed at a given volume and the fan unit 200 has a tendency to go intostall.

Examples of controllability are shown in FIGS. 13 and 14. In the fanarray fan section in the air-handling system shown in FIG. 13, the arraycontroller 300 alternates “ON” fan units 200 and “OFF” fan units 200 ina first exemplary pattern as shown so that the entire system is set tooperate at 52% of the maximum rated air flow but only consumes 32% offull rated power. These numbers are based on exemplary typical fanoperations in a structure. FIG. 14 shows the fan array fan section inthe air-handling system set to operate at 32% of the maximum rated airflow but only consumes 17% of full rated power. These numbers are basedon exemplary typical fan operations in a structure. In this embodiment,the array controller 300 creates a second exemplary pattern of “OFF” fanunits 200 and “ON” fan units 200 as shown.

Real Estate

The fan array fan section in the air-handling section 220 of the presentinvention preferably uses (60% to 80%) less real estate than prior artdischarge plenums 120 (with the hundred series number being prior art asshown in FIG. 1 and the two hundred series number being the presentinvention as shown in FIG. 3) in air-handling systems. Comparing theprior art (FIG. 1) and the present invention (FIG. 3) shows a graphicalrepresentation of this shortening of the airway path 120, 220. There aremany reasons that using multiple smaller fan units 200 can reduce thelength of the airway path 120, 220. For example, reducing the size ofthe fan unit 100, 200 and motor 108, 208 reduces the length of thedischarge plenum 110, 210. Similarly, reducing the size of the inletcone 104, 204 reduces the length of the inlet plenum 112, 212. Thelength of the discharge plenum 110, 210 can also be reduced because airfrom the fan array fan section in the air-handling system of the presentinvention is substantially uniform whereas the prior art air-handlingsystem has points of higher air velocity and needs time and space to mixso that the flow is uniform by the time it exits the air-handlingcompartment 102, 202. (This can also be described as the higher staticefficiency in that the present invention eliminates the need forsettling means downstream from the discharge of a prior art fan systembecause there is little or no need to transition from high velocity tolow velocity.) The fan array fan section in the air-handling systemtakes in air from the inlet plenum 212 more evenly and efficiently thanthe prior art air-handling system so that the length of the inlet plenum112, 212 may be reduced.

For purposes of comparison, the first exemplary structure set forth inthe Background of the Invention (a structure requiring 50,000 cubic feetper minute of air flow at a pressure of six (6) inches water gage) willbe used. Using the first exemplary structure an exemplary embodiment ofthe present invention could be served by a nominal discharge plenum 210of 89 inches high by 160 inches wide and 30 to 36 inches long (ascompared to 106 to 112 inches long in the prior art embodiments). Thedischarge plenum 210 would include a 3×4 fan array fan section in theair-handling system such as the one shown in FIG. 6) having 12 fan units200. The space required for each exemplary fan unit 200 would be arectangular cube of approximately 24 to 30 inches on a side depending onthe array configuration. The airway path 220 is 42 to 48 inches (ascompared to 88 to 139 inches in the prior art embodiments).

For purposes of comparison, the second exemplary structure set forth inthe Background of the Invention (a structure requiring 26,000 cubic feetper minute of air flow at a pressure of two (2) inches water gage) willbe used. Using the second exemplary structure, an exemplary embodimentof the present invention could be served by a nominal discharge plenum210 of 84 inches high by 84 inches wide, and and 30 to 36 inches long(as compared to 94 to 100 inches long in the prior art embodiments). Thedischarge plenum would include a 3×3 fan array fan section in theair-handling system (such as the one shown in FIG. 7) having 9 fan units200. The space required for each exemplary fan unit 200 would be arectangular cube of approximately 24 to 30 inches on a side depending onthe array configuration. The airway path 220 is 42 to 48 inches (ascompared to 71 to 95 inches in the prior art embodiments).

Reduced Production Costs

It is generally more cost effective to build the fan array fan sectionin the air-handling system of the present invention as compared to thesingle fan unit 100 used in prior art air-handling systems. Part of thiscost savings may be due to the fact that individual fan units 200 of thefan array can be mass-produced. Part of this cost savings may be due tothe fact that it is less expensive to manufacture smaller fan units 200.Whereas the prior art single fan units 100 were generally custom builtfor the particular purpose, the present invention could be implementedon a single type of fan unit 200. In alternative embodiments, theremight be several fan units 200 having different sizes and/or powers(both input and output). The different fan units 200 could be used in asingle air-handling system or each air-handling system would have onlyone type of fan unit 200. Even when the smaller fan units 200 are custommade, the cost of producing multiple fan units 200 for a particularproject is almost always less that the cost of producing a single largeprior art fan unit 100 for the same project. This may be because of thedifficulties of producing the larger components and/or the cost ofobtaining the larger components necessary for the single large prior artfan unit 100. This cost savings also extends to the cost of producing asmaller air-handling compartment 202.

In one preferred embodiment of the invention, the fan units 200 aremodular such that the system is “plug and play.” Such modular units maybe implemented by including structure for interlocking on the exteriorof the fan units 200 themselves. Alternatively, such modular units maybe implemented by using separate structure for interlocking the fanunits 200. In still another alternative embodiment, such modular unitsmay be implemented by using a grid system into which the fan units 200may be placed.

Reduced Operating Expenses

The fan array fan section in the air-handling system of the presentinvention preferably are less expensive to operate than prior artair-handling systems because of greater flexibility of control and finetuning to the operating requirements of the structure. Also, by usingsmaller higher speed fan units 200 that require less low frequency noisecontrol and less static resistance to flow.

Increased Efficiency

The fan array fan section in the air-handling system of the presentinvention preferably is more efficient than prior art air-handlingsystems because each small fan unit 200 can run at peak efficiency. Thesystem could turn individual fan units 200 on and off to preventinefficient use of particular fan units 200. It should be noted that anarray controller 300 could be used to control the fan units 200. As setforth above, the array controller 300 turns off certain fan units 200and runs the remaining fan units 200 at peak efficiency.

Redundancy

Multiple fan units 200 add to the redundancy of the system. If a singlefan unit 200 breaks down, there will still be cooling. The arraycontroller 300 may take disabled fan units 200 into consideration suchthat there is no noticeable depreciation in cooling or air flow rate.This feature may also be useful during maintenance as the arraycontroller 300 may turn off fan units 200 that are to be maintainedoffline with no noticeable depreciation in cooling or air flow rate.

Sound Attenuation Advantages

The high frequency sound of the small fan units 200 is easier toattenuate than the low frequency sound of the large fan unit. Becausethe fan wall has less low frequency sound energy, shorter less costlysound traps are needed to attenuate the higher frequency sound producedby the plurality of small fan units 200 than the low frequency soundproduced by the single large fan unit 100. The plurality of fan units200 will each operate in a manner such that acoustic waves from eachunit will interact to cancel sound at certain frequencies thus creatinga quieter operating unit than prior art systems.

Reduced Vibration

The multiple fan units 200 of the present invention have smaller wheelswith lower mass and create less force due to residual unbalance thuscausing less vibration than the large fan unit. The overall vibration ofmultiple fan units 200 will transmit less energy to a structure sinceindividual fans will tend to cancel each other due to slight differencesin phase. Each fan unit 200 of the multiple fan units 200 manage asmaller percentage of the total air handling requirement and thusproduce less turbulence in the air stream and substantially lessvibration.

Alternative Embodiments

As mentioned, in one preferred embodiment of the invention, the fanunits 200 are modular such that the system is “plug and play.” Suchmodular units may be implemented by including structure for interlockingon the exterior of the fan units 200 themselves. Alternatively, suchmodular units may be implemented by using separate structure forinterlocking the fan units 200. In still another alternative embodiment,such modular units may be implemented by using a grid system into whichthe fan units 200 may be placed.

FIG. 16 shows an embodiment using an exemplary grid system 230 intowhich the fan units 200 may be placed. In this embodiment the grid maybe positioned and/or built within the air-handling compartment 202. Thefan units 200 may then be positioned into the grid openings, Oneadvantage of this configuration is that individual fan units 200 may beeasily removed, maintained, and/or replaced. This embodiment uses anexemplary unique motor mount 232 that supports the motor 208 withoutinterfering with air flow therearound. As shown, this exemplary motormount 232 has a plurality of arms that mount around the fan inlet cone204. It should be noted that the dimensions of the grid are meant to beexemplary. The grid may be constructed taking into consideration thatthe fan units 200 in the present invention may be spaced with as littleas 20% of a fan wheel diameter between the fan units 200.

FIG. 17 shows an embodiment using either a grid system or modular units240 using separate structure (not shown) for interlocking the fan units200. In this exemplary embodiment, each of the fan units 200 are mountedon a more traditional motor mount 242 within its own fan unit chamber244. In one preferred embodiment, the fan unit 200 and motor mount 242are preferably suspended within their own fan unit chamber 244 such thatthere is an air relief passage 246 therebelow. This air relieve passage246 tends to improve air flow around the fan units 200.

The fan unit chambers 244 shown in FIG. 17 may include one ore moreinterior surface made from or lined with an acoustically absorptivematerial or “insulation surface” 248. Going against conventionalindustry wisdom that surfaces cannot be placed in close proximity withthe fan units 200, the present invention places one or more insulationsurfaces 248 at least partially around each fan unit 200 withoutdisrupting air flow. The insulation surfaces 248 may include one or moreof the sides, top, bottom, front, or back. Exemplary types of insulationinclude, but are not limited to traditional insulation board (such asthat made from inorganic glass fibers (fiberglass) alone or with afactory-applied foil-scrim-kraft (FSK) facing or a factory-applied allservice jacket (ASJ)) or alternative insulation such as open cell foamsuch as that disclosed in U.S. patent application Ser. No. 10/606,435,which is assigned to the assignee of the present invention, and whichthe disclosure of which is hereby incorporated by reference herein.Together, the insulation surfaces 248 on the fan unit chambers 244 tendto function as a coplanar silencer. Some of the benefits of using thecoplanar silencer include (1) no added airway length for splitters, (2)no pressure drop, and/or (3) relatively low cost. The acousticadvantages of this and other embodiments make the present inventionideal for use in concert halls, lecture halls, performing arts centers,libraries, hospitals, and other applications that are acousticallysensitive.

Although FIG. 17 shows the discharge plenum 210 positioned within thefan unit chambers 244, alternative embodiments of fan unit chambers 244could enclose the inlet plenum 212, or at least partially enclose boththe inlet plenum 212 and the discharge plenum 210. Still otheralternative embodiments of fan unit chambers 244 may have grid or wiresurfaces (that increase the safety of the present invention) or be open(that would reduce costs).

FIG. 18 shows an array of dampeners 250 that may be positioned either infront of or behind the fan units 200 to at least partially prevent backdrafts. In the shown exemplary embodiment, the dampeners 250 include aplurality of plates, each plate positioned on its own pivot. In theshown exemplary embodiment, the plurality of plates slightly overlapeach other. The shown embodiment is constructed such that when air isflowing through the fan units 200, the plates are in the open positionand when the air stops, gravity pulls the plates into the closedposition. Preferably, each of the dampeners 250 operates independentlysuch that if some of the fan units 200 are ON and some of the fan units200 are OFF, the dampeners 250 can open or close accordingly. Althoughshown as a simple mechanical embodiment, alternative embodiments couldinclude structure that is controlled electronically and/or remotely fromthe dampeners 250.

FIG. 19 shows airflow between the two panels 20 which representacoustically insulted surfaces and sound attenuation layers. FIGS. 19-21show a first embodiment in which a fiberglass core 22 has an open cellfoam 24 layered with at least one side of the fiberglass core 22. FIGS.19 and 21-24 show a second embodiment combining the use of open cellfoam 24 with for use of perforated rigid facing 26. FIGS. 24 and 25 showa third embodiment in which the entire insulation board 10 is replacedwith an uncoated open cell foam pad 22.

Turning first to the first embodiment shown in FIGS. 19-21, this layeredembodiment includes a fiberglass core 22 (or other type of insulation)that has an open cell foam 24 layered with at least one side of thefiberglass core 22. One advantage to using both the fiberglass materialand the open cell foam material is that it is less expensive than usingopen cell foam material alone because open cell foam more expensive thanfiberglass. Another advantage to using both the fiberglass material andthe open cell foam material is that it weighs less than using fiberglassmaterial alone because fiberglass weighs more than open cell foam.Another advantage to using both the fiberglass material and the opencell foam material is that is that the two materials provide differenttypes of acoustic insulation over a different range of frequencies.Together, the two materials provide sound absorption over greater rangeof frequencies. The graph below (shown with a vertical axis as theabsorption coefficient going from 0 to 1 and a horizontal axis showingthe frequency going from 0 to 10,000 Htz at approximately the peakpoint) is meant to be exemplary and does not necessarily reflectaccurate measurements.

Alternative embodiments of the first layered embodiment include afiberglass core 22 with one side layered with open cell foam 24 (FIG.19), a fiberglass core 22 with both sides layered with open cell foam 24(FIG. 20), and a fiberglass core 22 and layered with open cell foam 24secured by perforated rigid facing 26 (FIG. 21). The bottom section ofFIG. 24 shows the embodiment of FIG. 21 in use in an exemplary airhandler. It should also be noted that an alternative embodiment of thepresent invention could include more than two layers of different typesof insulation. For example, a four layer version could be open cellfoam, fiberglass, rockwool, and open cell foam. The layered embodimentcould actually be “tuned” using different types of insulations,different quantities of insulations, and different thicknesses ofinsulations to have the desired acoustic properties for the intendeduse.

The present invention also includes a method for making an air handlerusing the panels and layers. The method includes the steps of providingan air handler system with at least one air handler surface, providing acore of first insulation material having at least one layering surface,and providing a facing of open cell foam second insulation material.Then, the facing is at least partially layered to the at least onelayering surface to form a layered insulation board. Finally, the atleast one air handler surface is at least partially covered with thelayered insulation board so that the facing is exposed to airflowthrough the air handler.

Turning next to the second embodiment shown in FIGS. 19 and 21-24, thisperf-secured embodiment combines the use of open cell foam 24 with foruse of perforated rigid facing 26. Combining the use of open cell foamand perforated rigid facing 16 provides significant advantages for usein air handlers. For example, the use of the perforated rigid facing 26to secure the open cell foam 24 does not significantly reduce the soundabsorption qualities of the open cell foam 24. As shown in FIG. 22, theopen cell structure of the open cell foam 24 allows portions of the opencell foam 24 to protrude from openings defined in the perforated rigidfacing 26 (shown in front view in FIG. 23). The exposed open cell foam24 is able to absorb sound waves. In one embodiment, protruding opencell foam 24 formed between the openings in the perforated rigid facing26 absorbs sound waves. This can be compared to prior art embodiments inwhich sound waves are reflected by the substantially rigid diaphragmsformed by the smooth facing 14 being divided by the perforated rigidfacing 16.

Alternative embodiments of the second perf-secured embodiment include afiberglass core 22 and layered with open cell foam 24 secured byperforated rigid facing 26 (FIG. 21) and non-layered open cell foam 24secured by perforated rigid facing 26 (the bottom section of FIG. 24).It should be noted that alternative embodiments may replace perforatedrigid facing 26 shown in FIG. 23 with alternative securing structuresuch as perforated rigid facing 26 with alternatively shaped openings,straps, netting, wire grids, or other securing structure suitable toprevent the open cell foam 24 from being drawn inward.

The present invention also includes a method for making an air handlerusing the perf-secured embodiment. The method includes the steps ofproviding an air handler system with at least one air handler surface,providing open cell foam insulation material, and providing securingstructure through which said facing may be exposed. Then, the at leastone air handler surface is at least partially covered with the open cellfoam insulation material. Finally, the open cell foam insulationmaterial is secured to the at least one air handler surface so that theprotruding open cell foam insulation material is exposed to sound wavesand/or airflow through the air handler.

Turning next to the third preferred embodiment shown in FIGS. 24 and 25,in this uncoated embodiment combines the entire insulation board 10 isreplaced with uncoated open cell foam 24. This would be particularlysuitable for uses in which the presence of fiberglass would not besatisfactory for the intended use or would be unacceptable to theintended client. For example, pharmaceutical companies involved iningestible or injectable drugs would find it unacceptable to have anyfiberglass in the air handler. Alternative embodiments of the seconduncoated embodiment include uncoated open cell foam 24 secured byperforated rigid facing 26 (FIG. 24) uncoated open cell foam 24 securedin a frame 30 (FIG. 25).

The present invention also includes a method for making an air handlerusing the uncoated third embodiment. The method includes the steps ofproviding an air handler system with at least one air handler surfaceand open cell foam. The method also includes the step of covering atleast partially the at least one air handler surface with the open cellfoam.

The present invention is directed to the use of open cell foam in airhandlers that has the necessary durability, safety, and cleanlinessproperties for the particular use. One exemplary open cell foam,melamine foam (Melamine-Formaldehyde-Polycondensate), has been shown tobe quite suitable for this purpose. Melamine is a lightweight, hightemperature resistant, open cell foam that has excellent thermalproperties with superior sound absorption capabilities. Melamine iscleanable in that it is relatively impervious to chemicals (e.g. it isable to withstand relatively caustic cleaning agents such as SPOR-KLENZ®without breaking down). Melamine also meets the flame spread, smokedensity, and fuel contribution requirements necessary to comply withClass-I building code regulations. Because it does not shed particles,it can be used in places where fiberglass would be precluded. Stillfurther, as melamine is inert, it would not cause the health problems(such as those associated with fiberglass) for those who are exposed tothe product. It also is relatively attractive. It should be noted thatmelamine foam has been used as acoustic insulation by such companies asillbruk (www.illbruk-sonex.com). It should be noted that alternativeopen cell foams could be substituted for melamine. For example, siliconeor polyethane foam could be used as the open cell foam of the presentinvention.

It should be noted that the present invention has been primarilydiscussed in terms of fiberglass as an alternative type of insulation.It should be noted that other types of insulation may be used in placeof fiberglass including, but not limited to rockwool.

Although the embodiments are discussed in terms of layering fiberglassmaterial and the open cell foam material, alternative embodiments couldinclude, bonding the fiberglass material to the open cell foam material,enclosing the fiberglass material within the open cell foam material,coating the fiberglass material with an open cell foam material, andother means for layering the two materials. The term “layers” or“layering” are meant to encompass all of these embodiments as well asothers that would be known to those skilled in the art.

It should be noted that the term “air handlers” is meant to include, byway of example, recirculation air handlers, central air handlers,silencer, splitters (such as parallel splitters), clean room ceilingsystems, and commercial/industrial air handling systems.

It should be noted that FIG. 4 shows a 4×6 fan array fan section in theair-handling system having twenty-four fan units 200, FIG. 5 shows a 5×5fan array fan section in the air-handling system having twenty-five fanunits 200, FIG. 6 shows a 3×4 fan array fan section in the air-handlingsystem having twelve fan units 200, FIG. 7 shows a 3×3 fan array fansection in the air-handling system having nine fan units 200, and FIG. 8shows a 3×1 fan array fan section in the air-handling system havingthree fan units 200. It should be noted that the array may be of anysize or dimension of more than two fan units 200. It should be notedthat although the fan units 200 may be arranged in a single plane (asshown in FIG. 3), an alternative array configuration could contain aplurality of fan units 200 that are arranged in a staggeredconfiguration (as shown in FIG. 15) in multiple planes. It should benoted that cooling coils (not shown) could be added to the system eitherupstream or downstream of the fan units 200. It should be noted that,although shown upstream from the fan units 200, the filter bank 122, 222could be downstream.

It should be noted that an alternative embodiment would use ahorizontally arranged fan array. In other words, the embodiments shownin FIGS. 3-15 could be used horizontally or vertically or in anydirection perpendicular to the direction of air flow. For example, if avertical portion of air duct is functioning as the air-handlingcompartment 202, the fan array may be arranged horizontally. Thisembodiment would be particularly practical in an air handlingcompartment for a return air shaft.

It should be noted that the fan section 214 may be any portion of theairway path 220 in which the fan units 200 are positioned. For example,the fan units 200 may be situated in the discharge plenum 210 (asshown), the inlet plenum 212, or partially within the inlet plenum 212and partially within the discharge plenum 210. It should also be notedthat the air-handling compartment 202 may be a section of air duct.

The terms and expressions that have been employed in the foregoingspecification are used as terms of description and not of limitation,and are not intended to exclude equivalents of the features shown anddescribed or portions of them. The scope of the invention is defined andlimited only by the claims that follow.

1. A fan array fan section in an air-handling system to supply air to abuilding, comprising: an air handling compartment having a dischargeplenum configured to deliver air to a ventilation system for at least aportion of the building; a fan array of at least three fan unitspositioned in the air handling compartment, the fan units having motorsand fans, the motors having a corresponding nameplate rated speed, thefans being configured to deliver an air flow amount based on a speed ofthe corresponding motor; a speed controller to operate at least one ofthe motors at a first speed that is equal to or below the nameplaterated speed to deliver a first air flow amount from a corresponding oneof the fans; and the speed controller to operate the at least one of themotors at a second speed that is greater than the nameplate rated speedto deliver a second air flow amount from the corresponding one of thefans.
 2. The fan array fan section of claim 1, wherein the number of fanunits includes at least six fan units.
 3. The fan array fan section ofclaim 1, wherein the fan array is arranged in a 2-dimensional pattern.4. The fan array fan section of claim 1, wherein a wheel diameter of thefans substantially equals or is between 12 inches and 44 inches.
 5. Thefan array fan section of claim 1, wherein the wheel diameter of the fanssubstantially equals or is between 12 inches and 25 inches.
 6. The fanarray fan section of claim 1, wherein spacing between said fan units isbetween 60% and 20% of said fan wheel diameter.
 7. The fan array fansection of claim 1, further comprises a grid system of grid cells inwhich the fan units are placed.
 8. The fan array fan section of claim 1,wherein the fans constitute plenum fans.
 9. The fan array fan section ofclaim 1, wherein the speed controller includes a variable frequencydrive.
 10. The fan array fan section of claim 1, wherein fan arrayincludes a number of fan units sufficient to at least meet a total airhandling requirement for at least the portion of the building, andwherein the speed controller is sized to meet a power consumption of thefan array needed to meet the total air handling requirement.
 11. The fanarray fan section of claim 1, wherein the fans are coupled to the motorsin a direct drive connection.
 12. The fan array fan section of claim 1,wherein a wheel diameter of the fans is substantially equal to orgreater than 20 inches.
 13. A method of implementing a fan array airhandling system to supply air to a building, the air handling systemincluding an air handling compartment having a discharge plenumconfigured to deliver air to a ventilation system for at least a portionof the building; the method comprising: obtaining a fan array of atleast three fan units positioned in the air handling compartment, thefan units having motors and fans, the motors having a correspondingnameplate rated speed, the fans being configured to deliver an air flowamount based on a speed of the corresponding motor; configuring a speedcontroller to operate at least one of the motors at a first speed thatis equal to or below the nameplate rated speed to deliver a first airflow amount from a corresponding one of the fans; and configuring thespeed controller to operate the at least one of the motors at a secondspeed that is greater than the nameplate rated speed to deliver a secondair flow amount from the corresponding one of the fans.
 14. The methodof claim 13, wherein the number of fan units includes at least six fanunits.
 15. The method of claim 13, wherein the fan array is arranged ina 2-dimensional pattern.
 16. The method of claim 13, further comprisingsizing a wheel diameter of the fans to be substantially equal or between12 inches and 44 inches.
 17. The method of claim 13, further comprisingsizing a wheel diameter of the fans to be substantially equal or between12 inches and 25 inches.
 18. The method of claim 13, wherein the fanarray at least meets a specified air capacity that corresponds to atotal air handling requirement of a structure.
 19. The method of claim13, further comprising managing flow of air within the air handlingcompartment to exhibit a substantially uniform airflow at a back end ofthe air handling compartment.
 20. The method of claim 13, furthercomprising positioning sound attenuation layers between at least aportion of adjacent fan units, wherein the air handling compartmentincludes multiple chambers and the fan units are positioned incorresponding chambers of the air handling compartment and are arrangedadjacent to one another.
 21. The method of claim 20, wherein the fanunits are positioned adjacent to one another in a common plane, thesound attenuation layers being arranged in at least one of rows andcolumns, to traverse the common plane.
 22. The method of claim 20,wherein the sound attenuation layers are provided along each of the top,bottom, and sides of the corresponding chambers.
 23. The method of claim20, wherein the sound attenuation layers include a perforated facing andat least one layer of insulation material.
 24. The method of claim 20,wherein the sound attenuation layers extend from front ends to back endsof the corresponding chambers.
 25. The method of claim 20, wherein thesound attenuation layers are located along, and enclose, top, bottom andsides of the fans and motors in the corresponding chambers.
 26. Themethod of claim 13, wherein the speed controller includes a variablefrequency drive.
 27. The method of claim 13, wherein fan array includesa number of fan units sufficient to at least meet a total air handlingrequirement for at least the portion of the building, and wherein thespeed controller is sized to meet a power consumption of the fan arrayneeded to meet the total air handling requirement.
 28. The method ofclaim 13, wherein the fans are coupled to the motors in a direct driveconnection.
 29. The method of claim 13, wherein a wheel diameter of thefans is substantially equal to or greater than 20 inches.
 30. The fanarray fan section of claim 1, wherein the air handling compartmentincludes multiple chambers arranged in an array where at least a portionof the chambers are located adjacent to one another in at least one rowor column; wherein the fan units are positioned in correspondingchambers of the air handling compartment and are arranged adjacent toone another; and at least a portion of the chambers including soundattenuation layers that extend along at least one of a top, bottom andsides of the corresponding chambers, the sound attenuation layers atleast partially surrounding the corresponding fans and motors, at leasta portion of the sound attenuation layers being positioned between thechambers adjacent to one another.
 31. The fan array fan section of claim30, wherein the fan units are positioned adjacent to one another in acommon plane, the sound attenuation layers being arranged in at leastone of rows and columns, to traverse the common plane.
 32. The fan arrayfan section of claim 30, wherein the sound attenuation layers areprovided along each of the top, bottom, and sides of the correspondingchambers.
 33. The fan array fan section of claim 30, wherein the soundattenuation layers include a perforated facing and at least one layer ofinsulation material.
 34. The fan array fan section of claim 30, whereineach of the chambers has a front end and a back end, wherein the fanunits are oriented such that the fans are located proximate to the frontends of the chambers and the motors extend toward the back ends of thechambers.
 35. The fan array fan section of claim 34, wherein the soundattenuation layers extend from the front ends to the back ends of thecorresponding chambers.
 36. The fan array fan section of claim 30,wherein each of the fan units is positioned in a correspondingindividual one of the chambers.
 37. The fan array fan section of claim30, wherein the sound attenuation layers are located along, and enclose,the top, bottom and sides of the fans and motors in the correspondingchambers.
 38. The fan array fan section of claim 30, wherein a spacingbetween an outer periphery of the fans in adjacent chambers is between20% and 60% of a fan wheel diameter.
 39. The fan array fan section ofclaim 30, wherein a spacing between an outer periphery of the fans inadjacent chambers is between 30% and 60% of a fan wheel diameter. 40.The fan array fan section of claim 30, wherein the fan units direct airinto a common area of the discharge plenum where the air combines beforeexiting the discharge plenum.